Methods of manufacturing articles utilizing foam particles

Abstract

Methods for manufacturing components of articles, including articles of footwear, apparel, and sporting equipment are provided. The disclosed methods comprise extruding a first composition comprising a plurality of foam particles suspended in a first material, wherein each particle of the plurality of foam particles is formed of a foamed second polymeric material; and solidifying the extruded first composition, forming a component. Also disclosed are first compositions comprising a first material and a plurality of foam particles comprising a foamed second polymeric material suspended in the first material. Articles and methods of manufacturing articles using the disclosed methods and compositions are also provided. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

What is claimed is: 
     
         1 . A method of manufacturing a component, the method comprising:
 extruding a first composition comprising a plurality of foam particles suspended in a first material, wherein each particle of the plurality of foam particles is formed of a foamed second polymeric material; and   solidifying the extruded first composition, forming a component.   
     
     
         2 . The method according to  claim 1 , wherein the first material is a first thermoplastic material, and the extruding comprises increasing at least a portion of the first polymeric material to a temperature above a softening or melting temperature of the first thermoplastic material, but below the melting temperature of the second polymeric material of the plurality of foam particles. 
     
     
         3 . The method according to  claim 2 , wherein the first material is a first thermoplastic material, and the method further comprises forming the first composition by increasing a temperature of the first thermoplastic material to a temperature at or above the melting temperature of the first thermoplastic material but below a melting temperature of the second polymeric material, and suspending the plurality of foam particles in the molten first polymeric material prior to the extruding. 
     
     
         4 . The method according to  claim 3 , wherein the forming the first composition comprises increasing the temperature of the first thermoplastic material to a temperature at or above the melting temperature of the first thermoplastic material but at least 20 degrees C. below the melting temperature of the second polymeric material. 
     
     
         5 . The method according to  claim 4 , wherein the forming the first composition comprises increasing the temperature of the first thermoplastic material to a temperature at or above the melting temperature of the first thermoplastic material but at least 10 degrees C. below a Vicat softening temperature of the second polymeric material. 
     
     
         6 . The method according to  claim 1 , wherein the extruding comprises extruding the first composition onto a second component, and the solidifying comprises solidifying the extruded first composition in contact with the second component, bonding the extruded first composition to the second component. 
     
     
         7 . The method according to  claim 1 , wherein the method further comprises shaping the extruded first composition prior to the solidifying, and the solidifying comprises solidifying the shaped extruded first composition. 
     
     
         8 . The method according to  claim 1 , wherein the extruding and shaping comprise one or more iterations of extruding a first layer of the first composition, then extruding a second layer of the first composition onto the first layer, and bonding the second layer to the first layer. 
     
     
         9 . The method according to  claim 8 , wherein the extruding and shaping comprise 2 to 50 of the iterations. 
     
     
         10 . The method according to  claim 1 , further comprising decorating the component. 
     
     
         11 . The method according to  claim 10 , wherein the decorating comprises applying a coating to the component, or embossing or debossing the component, or both. 
     
     
         12 . A first composition comprising:
 a first material; and   a plurality of foam particles comprising a foamed second polymeric material suspended in the first material.   
     
     
         13 . The first composition according to  claim 12 , wherein the first composition comprises from about 1 part to about 50 parts per hundred of the foam particles per part of the first material on a weight basis. 
     
     
         14 . The first composition according to  claim 12 , wherein the first material is a thermoplastic material, wherein the first thermoplastic material comprises a thermoplastic polyurethane, a thermoplastic polyester, or a thermoplastic polyamide, wherein the foamed second polymeric material of the plurality of foam particles comprises a polymer selected from the group consisting of: polyesters, polyamides, vinyl polymers, polyolefins, polyacrylonitriles, polyphenylene ethers, polycarbonates, polyureas, styrene polymers, co-polymers thereof, and combinations thereof. 
     
     
         15 . The first composition according to  claim 14 , wherein the first thermoplastic material has a melting temperature that is at least 10 degrees C. lower than the melting temperature of the foamed second polymeric material of the plurality of foam particles. 
     
     
         16 . The first composition according to  claim 12 , wherein the plurality of foam particles comprise foam particles having a density of about 0.1 grams per cubic centimeter to about 0.8 grams per cubic centimeter. 
     
     
         17 . An article comprising a component comprising the first composition according to any one of  claim 12 . 
     
     
         18 . The article according to  claim 17 , wherein the article is a component of an article of footwear, apparel, or sporting equipment, 
     
     
         19 . The article according to  claim 18 , wherein the component of an article of footwear, apparel or sporting equipment is a cushioning element for an article of footwear or an impact absorbing element. 
     
     
         20 . The article according to  claim 19 , wherein the cushioning element for an article of footwear is a midsole, an outsole, a combination midsole-outsole unit, a sock-liner, an ankle collar, or a heal-cushioning pad.